Process for providing fluorescence to a dental ceramic body

ABSTRACT

A process for providing fluoresence to a dental ceramic body by treating at least a portion of the outer surface of the dental ceramic body or a precursor thereof with a bismuth containing substance, characterized by the steps of placing the dental ceramic body or the precursor thereof into a closeable container, in particular a crucible; generating a bismuth containing atmosphere in the container and exposing at least a portion of the outer surface of the dental ceramic body or of the precursor to the bismuth containing atmosphere at a temperature above 1000° C.

This is a Division of application Ser. No. 15/549,321 filed Aug. 7,2017, now U.S. Pat. No. 10,662,120, which is a National Phase ofInternational Application No. PCT/EP2016/052543 filed Feb. 5, 2016,which in turn claims the benefit of European Application No. 15000339.0filed Feb. 5, 2015. The disclosure of the prior applications is herebyincorporated by reference herein in its entirety.

The present invention relates to a process for providing fluorescence toa dental ceramic body.

The present invention further relates to a dental ceramic body, inparticular to a prosthetic element for use in a dental restoration.

The aestethics of a dental restoration depends to an important part onits translucency and color, which ideally closely resemble the one of anatural tooth.

From an aestethical point of view, ceramics, such as zirconia and/oralumina ceramics, are particularly well suited as restorative materials,because of their ability to provide excellent cosmetic results owed totheir colour and their adequate reflection and transmission of light. Inaddition, these ceramics are biocompatible and exhibit good mechanicalstrength when subjected to masticatory efforts.

In order to adequately mimick the appearance of a natural tooth, alsoits inherent luminescence, in particular the of the dentin tissue, needsto be taken into account.

Fluorescence refers to the phenomenon of light being emitted by asubstance that has absorbed light or other electromagnetic radiation.Typically, the emitted light is of longer wavelength and, therefore,lower energy than the absorbed radiation.

In a natural tooth, the fluorescent properties are such that ultravioletlight is absorbed and visible light in the blue spectrum is emitted. Dueto the high amount of light in the blue spectrum generated, a naturaltooth often appears whiter and brighter in daylight than restorativematerials.

Efforts have, thus, been taken to adapt the fluorescence intensities ofrestorative materials as closely as possible to that of human teeth, inparticular the enamel and dentin tissue, to ensure an acceptablereproduction of these qualities in aestethic restorations.

US 2012/0012789, for example, relates to a fluorescent zirconia materialas a dental material comprising a fluorescent component and emittingfluorescence when excited with a light of a predetermined wavelength.The fluorescent component includes a fluorescent material including atleast one kind of Y₂SiO₅:Ce, Y₂SiO₅:Tb, (Y, Gd, Eu)BO₃, Y₂O₃:Eu, YAG:Ce,ZnGa₂O₄:Zn and BaMgAl₁₀O₁₇:Eu. According to US 2012/0012789, thefluorescent material is mixed in the form of fluorescent powder to theraw material powder.

FR 2 781 366 A1 relates to a dental ceramic composition essentiallyconsisting of yttria-stabilized zirconia, a colouring filling materialand impurities, the colouring filling material consisting of Fe₂O₃,Bi₂O₃ and CeO₂. The content of Fe₂O₃ is according to FR 2 781 366 A1preferably between 0.03 wt.-% and 0.1 wt.-%.

Further, WO 2014/164199 deals with the problem of mimicking the naturaltooth appearance in dental restorations taking into account theindividual degrees of color and brightness of the hard dental tissues,e.g. of enamel and dentin. In this regard, WO 2014/164199 suggests asolution for colouring and imparting fluorescence to a zirconia dentalarticle, the solution comprising a solvent, a colouring agent comprisingions selected from Tb, Er, Pr, Mn and combinations thereof, and afluorescing agent comprising ions of Bi.

A solution for treating the surface of a pre-sintered dental ceramic isfurther disclosed in WO 2013/022612. Specifically, WO 2013/022612 aimsat avoiding a complete diffusion of the composition into the pores ofthe pre-sintered dental ceramic so that a defined application of thecolouring solution can be accomplished. To this end, WO 2013/022612suggests a non-water based solution comprising a solvent other thanwater, an effect agent causing either colouring, providing fluorescenceor a combination thereof, and a complexing agent.

Both the solutions suggested in WO 2013/022612 and in WO 2014/164199 areto be applied on a porous dental article, typically by means of a brush.According to WO 2014/164199, the preferred time of treatment ispreferably 1 to 3 minutes.

Often, there is the case that the dental ceramic already has the desiredcolour, but needs to be provided with fluorescence only, i.e. withoutchanging the colour. If this is to be achieved by treating the dentalceramic with a solution according to e.g. WO 2013/022612, drying of thetreated dental ceramic is typically required in order to avoid i.a.inhomogeneous colour effects. Inhomogeneities in the colouring can inparticular arise from the method of applying the solution, as it is forexample the case when using a brush.

According to both WO 2013/022612 and WO 2014/164199, drying of thetreated ceramic article typically takes about 1 to 3 hours. Overall, thetreatment of the ceramic with the solution and and the drying of thesolution results in a time-consuming process.

In order to streamline the process of providing fluorescence to a dentalceramic body, a time-saving but nevertheless simple process would bedesirable.

The problem to be solved by the present invention is, thus, to provide aprocess for providing fluorescence to a dental ceramic body in a simpleand time-saving manner.

The problem is solved by the process for providing fluorescence to adental ceramic body disclosed herein. Preferred embodiments of theinvention are defined in the claims.

The present invention relates to a process for providing fluorescence toa dental ceramic body by treating at least a portion of the outersurface of the dental ceramic body or a precursor thereof with a bismuthcontaining medium.

The process is characterized by the steps of

-   -   a) placing the dental ceramic body or the precursor thereof into        a closeable container, in particular a crucible;    -   b) generating a bismuth containing atmosphere in the container        and    -   c) exposing at least a portion of the outer surface of the        dental ceramic body or of the precursor to the bismuth        containing atmosphere at a temperature above 1000° C.

It has surprisingly been found that at a temperature above 1000° C.,bismuth, in particular in the form of bismuth oxide, penetrates into thedental ceramic body in an amount sufficient for providing fluorescenceclosely resembling the one of a natural tooth. In this context, bismuthcan also be referred to as a “dopant”.

Specifically, the dopant bismuth diffuses into the ceramic material,whereby it moves through the crystal lattice of the ceramic material.This can take place in different ways, e.g. by empty space diffusion,whereby the dopant fills an empty place present in the crystal lattice.Alternatively or additional, the dopant can diffuse by inter latticediffusion, whereby it moves in-between the atoms in the crystal lattice,or by changing of places, whereby the dopant is located in the crystallattice and exchanged with a crystal lattice atom.

Unlike the processes suggested in the state of the art mentioned above,in particular in WO 2013/022612 and in WO 2014/164199, the process ofthe present invention allows providing fluorescence to the body withoutapplying a solution comprising the fluorophor. The time-consuming stepsof applying and drying the solution can thus be obviated.

Specifically and as will be discussed in further detail below, thepresent invention allows the process of providing fluorescence to beintegrated in the sintering step and/or at least one of thepost-sintering steps, e.g. the white firing, for preparing the denseceramic body. Due to the fact that bismuth, specifically in the form ofbismuth oxide, is incorporated into the ceramic material simultaneouslywith at least one of the process steps that are normally performed forpreparing the ceramic body, a very time-saving process can ultimately beachieved.

In addition, the present invention allows a homogeneous fluorescence tobe provided, given the fact that the entire surface to be exposed isvirtually facing the same atmosphere during step c). Inhomogeneitiesthat might arise when e.g. a fluorophor containing solution is appliedby means of a brush, i.e. the typical application method according to WO2013/022612, can thus be avoided.

Due to the fluorophor being bismuth, specifically in the form of bismuthoxide, a broad excitation spectrum as well as an emission spectrumresembling the one of a natural tooth can be achieved. In particular, abroad excitation spectrum and a whitish-blue emission can be achieved.

Further, the present invention allows the desired fluorescence to becombined with a colouring of the dental ceramic body, which is typicallyperformed before providing fluorescence. In particular, the desiredfluorosence can be applied on a coloured dental ceramic body byintroducing bismuth, specifically in the form of bismuth oxide, in anamount at which there is no or no substantial discoloration.

As will be explained in more detail below, the fluorescence intensitycan be easily tuned by adapting the amount of bismuth contained in thebismuth containing atmosphere.

Although the present invention allows bismuth, specifically in the formof bismuth oxide, to penetrate into the ceramic material in an amountsufficient to provide the desired fluorescence, the amount can still bekept low enough not to have a negative impact on the mechanicalstability of the dental ceramic body. In particular, the tetragonalphase stability of zirconia is not influenced in a negative way by thedoping with bismuth.

In addition, the biocompatibility of the dental ceramic body is notaffected by the process of the present invention.

The term “dental ceramic body” as used in the context of the presentinvention relates to any ceramic body suitable in the field ofdentistry. The term can relate both to a pre-sintered ceramic body(often referred to as the “porous ceramic body”, to a sintered ceramicbody (often referred to as the “dense ceramic body”) or to a ceramicbody after at least one post-sintering step, e.g. white firing.Accordingly, the term “precursor” can in particular relate to the greenbody obtained by pressing the respective ceramic powder.

Preferably, the dental ceramic body comprises or essentially consists ofzirconia and/or alumina. In particular zirconia shows outstandingproperties with regard to aestethic appearance and mechanicalproperties.

It is further preferred that the ceramic material of the body, inparticular zirconia and/or alumina, is devoid of any metal that mightquench the fluorescent properties provided by bismuth. Preferably, theceramic material is devoid of iron (Fe).

According to a particular preferred embodiment, the dental ceramic bodycomprises or essentially consists of yttria-stabilized zirconia. Byusing yttria-stabilized zirconia, a body having a particularly highmechanical strength can be achieved.

In this regard, the term “yttria-stabilized zirconia”encompasses—besides purely yttria-stabilized zirconia—anyyttria-stabilized zirconia that is co-stabilized with a co-stabilizingagent, such as cerium, calcium, erbium and/or magnesium or theirrespective oxides.

Also, the term “yttria-stabilized zirconia” encompasses both a materialbased on zirconia particles co-precipitated with yttria as well as amaterial based on yttria-coated zirconia particles.

An example of an yttria-stabilized zirconia based on zirconia particlesco-precipitated with yttria is ZrO₂-TZP/TZP-A Bio-HIP® (ZrO₂) Bioceramicof Metoxit AG, Switzerland. The composition of this ceramic materialcomprises 92.1 to 93.5 weight-% ZrO₂, 4.5 to 5.5 weigth-% Y₂O₃, 1.8 to2.2 weight-% HfO₂ and 0.25 weight-% Al₂O₃. It offers a particularly highmechanical stability and strength, in particular when prepared by hotisostatic pressing or by sintering with subsequent hot isostaticdensification. A detailed description of the ceramic material is givenin U.S. Pat. No. 6,165,925, the disclosure of which is incorporatedherein in its entirety by reference.

Apart from yttria-stabilized zirconia, also e.g. ceria-stabilized ormagnesia-stabilized zirconia as well as zirconia stabilized withstrontium, ytterbium, gadolinium, calcium, erbium or neodymium or theiroxides, respectively, are thinkable and also encompassed by the term“dental ceramic” according to the present invention.

The dental ceramic body or the precursor thereof is according to step a)placed into a closeable container, particularly a crucible, moreparticularly a sintering crucible.

After step a), i.e. after placing the dental ceramic body or theprecursor thereof into the container, a bismuth containing atmosphere isgenerated in the container in step b).

Typically, the bismuth containing atmosphere is generated by theevaporation of a bismuth compound from a bismuth source containing thebismuth compound. In this regard, it is preferred that the bismuthsource is placed in a region of the container other than the regionwhere the dental ceramic body is placed. Bismuth, in particular in theform of bismuth oxide, is according to this embodiment only incorporatedinto the ceramic material by way of exposure to the bismuth containingatmosphere; there is, however, no contact of the body with a bismuthcontaining substance other than the bismuth containing atmosphere. Inparticular, there is no direct application of a bismuth containingsolution on the dental ceramic body.

The fluorescence intensity to be provided can be adjusted byappropriately choosing the distance between the dental ceramic body andthe bismuth source and/or the concentration of bismuth in the bismuthcontaining atmosphere, which is again governed by the amount of thebismuth compound contained in the bismuth source. Further, it ispossible to mask areas of the outer surface of the dental ceramic bodyat least partially, in order to selectively provide non-fluorescentareas or areas of attenuated fluorescence intensity.

Thus, the process of the present invention allows for a relativelysimple adjustment of the fluorescent properties of the dental ceramicbody to the actual needs.

Alternatively to the bismuth compound being evaporated in the container,it is also thinkable to produce a bismuth containing gas outside of thecontainer, said gas being then introduced into the container to generatethe bismuth containing atmosphere therein.

As mentioned, the container, into which the dental ceramic body or itsprecursor is placed and in which a bismuth containing atmosphere isgenerated, is preferably a crucible. Alternatively, it can also be afurnace.

By the use of a crucible as closeable container, a stagnant bismuthcontaining atmosphere can be obtained even if a relatively moderateamount of bismuth compound in the bismuth source is provided, saidatmosphere containing bismuth in a concentration sufficient to allow forbismuth, in particular in the form of bismuth oxide, penetrating intothe ceramic body to provide it with the desired fluorescent properties.If exposure to the bismuth containing atmosphere is to be carried out ina conventional furnace, higher amounts of bismuth are necessary toachieve the desired effect, due to the large volume of the furnace andthe aeration typically present in the furnace.

The bismuth source containing the bismuth compound to be evaporated canbe a liquid bismuth source, in particular containing or essentiallyconsisting of molten bismuth oxide, a solution of bismuth nitrate,specifically bismuth nitrate pentahydrate, and/or a solution of bismuthacetate. In this regard, the liquid bismuth source can in some cases bedried and, hence, become solid before generating the bismuth containingatmosphere. Alternatively, a bismuth source can be used, which ab initiois solid, in particular bismuth-infiltrated zirconia and/or alumina.

According to a preferred embodiment, the crucible confines an innerspace having a volume in the range from 50 to 200 cm³, typically ofabout 100 cm³.

The container, and specifically the crucible, can for example be made ofalumina, platinum or a platinum alloy, specifically platinum-rhodium. Inparticular in view of embodiments, in which the bismuth source containsa relatively high amount of a bismuth compound, the container ispreferably made of platinum or a platinum alloy.

Given the high heat-resistance of platinum or a platinum alloy,specifically of platinum-rhodium, a temperature of higher than 1400° C.can be chosen in step c) without negative consequences for the crucible,thereby allowing all of the bismuth compound entering the gas phase,even in the case where a high amount of bismuth compound is provided.Consequently, a container of relatively large volume can be chosen,thereby also allowing to treat multiple dental ceramic bodies in one andthe same crucible simultaneously.

In particular in view of treating multiple dental ceramic bodiessimultaneously, the bismuth containing source is preferably placed in acentral area of the crucible, which upon heating gives rise to a uniformenvironment for bodies that are equidistantly disposed around thebismuth source.

If necessary or appropriate, the bismuth source can placed in arespective vessel, such as an alumina vessel, arranged in the crucible.

Typically, the bismuth containing atmosphere contains bismuth in theform of bismuth oxide. This is in particular the case when an oxidizingatmosphere, e.g. air, is present, in which bismuth oxide is generatedalso in the case when the bismuth source contains e.g. bismuth nitratepentahydrate.

Accordingly, it is further preferred that at least steps b) and c) areperformed in the presence of oxygen, and most preferably in the presenceof air. In this particular case, the bismuth containing atmosphererelates to air additionally containing bismuth oxide.

According to a particularly preferred embodiment, the atomic mass ofbismuth in the bismuth source placed in the container is the range of0.5 to 1000 mg per liter of volume of the container's inner space.

Accordingly, it is further preferred that the molar concentration ofbismuth in the bismuth containing atmosphere is in the range from about1·10⁻⁶ to about 1·10⁻² mol/liter, more preferably from about 2·10⁻⁶ toabout 5·10⁻³ mol/liter. In this context, the concentration of bismuthrelates to any form of bismuth present in the atmosphere, and inparticular encompasses bismuth oxide.

It has further been found that the exposure to the bismuth containingatmosphere under step c) of the process of the present invention ispreferably performed at a temperature above 1200° C., preferably at atemperature above 1300° C. A temperature at about 1450° C.,corresponding to a typical sintering temperature for yttria-stabilizedzirconia ceramic, is particularly preferred due to the fact that at thistemperature bismuth, in particular in the form of bismuth oxide,efficiently diffuses into the body. At this particularly preferredtemperature, there is thus no discoloration which might arise when arelatively high amount of bismuth is deposited on the ceramic withoutdiffusing into the body and therefore accumulating on the outer surfaceof the body, rather than being incorporated in the body.

As mentioned above, fluorescence is according to the present inventionprovided by bismuth, specifically in the form of bismuth oxide,penetrating into the dental ceramic body and thereby becomingincorporated into the ceramic material.

The depth of penetration of bismuth, in particular in the form ofbismuth oxide, is preferably 500 μm at most, more preferably 400 μm atmost, most preferably 300 μm at most. According to a specificembodiment, the depth of penetration is in the range from 200 μm to 250μm.

As also mentioned above, the providing of fluorescence is preferablyintegrated in the sintering step and/or at least one of thepost-sintering steps normally performed when preparing the dentalceramic body. According to a particularly preferred embodiment, steps b)and c) are performed during sintering the dental ceramic body and/orduring a post-sintering step, since this allows a fluorescent ceramicbody to be obtained in a most time-saving manner. In this regard, theperforming of steps b) and c) during the sintering step is of particularrelevance, since at the sintering temperature a highly efficientpenetration of bismuth, specifically in the form of bismuth oxide, isachieved.

According to a specifically preferred embodiment, the present inventionthus relates to a process comprising the steps of providing fluoresenceto a dental ceramic body by treating at least a portion of the outersurface of the dental ceramic body or a precursor thereof with a bismuthcontaining substance, characterized by the steps of

-   α) placing a precursor of the dental ceramic body thereof into a    sintering crucible;-   β) generating a bismuth containing atmosphere in the sintering    crucible and-   γ) sintering the precursor to the dental ceramic body whereby at    least a portion of the outer surface of the precursor is exposed to    the bismuth containing atmosphere.

Alternatively, it can also be preferred to perform steps b) and c)during a post-sintering step, and more particularly during the finalpost-sintering step. This is in particular the case when the lowertemperature present during the post-sintering steps is sufficient for anefficient incorporation of bismuth and if loss of bismuth alreadyincorporated into the ceramic material, which potentially can occurduring heat treatment, shall be diminished.

Since fluorescence is according to the described process obtained bybismuth, in particular in the form of bismuth oxide, penetrating intothe dental ceramic body and since the fluorophor is therefore onlypresent in a surface-near region reaching down from the surface to thedepth of penetration, the body is particularly well suited forapplications for which no or only unsubstantial further machining isrequired in order obtain the final dental article. This can e.g. be thecase if the final dental article is a prosthetic element, the shape ofwhich corresponds essentially to the form of the densily sintered dentalceramic body.

For these applications, pre-sintered blocks are typically pre-shapedwith the aid of CAD/CAM systems into the shape of the prostethicelement, but having a size 25 to 30% higher than the final element tocompensate for the sintering shrinkage. The final sintering temperatureis between 1350° C. and 1550°. Apart from bismuth or the bismuthcontaining compound penetrating into the body, this processing reducesthe level of tension present and prevents the transformation from thetetragonal phase to the monoclinic phase, which leads to a final surfacevirtually free of the monoclinic phase.

According to a further preferred embodiment of the process, the dentalceramic body to which fluorescence is to be provided is, therefore, adental article, preferably an implant or a prosthetic element for use ina dental restoration, more preferably a crown, a bridge, an abutment, anonlay and/or an inlay.

The relevance of the dental ceramic body for use as a dental implant canbe explained by the fact that any loss of natural bone structure, e.g.as a result of bone resorption, can result in soft-tissue shrinkage dueto the lack of boney support, which ultimately can lead to the situationthat a portion of the implant becomes visible. Since the dental implantaccording to the present invention can both in colour and luminescencebe closely adapted to the colour and luminescence of a natural tooth, anunestethic situation can be circumvented also under these circumstances.

In addition to the process described above, the present inventionfurther relates to a dental ceramic body obtainable by the process.

In this regard, the present invention specifically relates to a dentalceramic body based on zirconia and/or alumina comprising or essentiallyconsisting of

a core region being at least essentially free of bismuth and

a surface region surrounding the core region and containing bismuth,

characterized in that the surface region in which bismuth is containedreaches down from the surface to a depth of 500 μm at most.

Given the fact that bismuth is only contained in a surface region, butis in essence absent from the remainder of the body, any impact of thechange in the material on the body's mechanical properties can be keptto a minimum.

In restricting the presence of bismuth to the surface region, i.e. downto a depth of 500 μm at most, the present invention is in clear contrastto technologies, which aim at a relatively deep penetration of thefluorescing agent. In particular, the present invention is in contrastto the technology taught in WO 2014/164199, according to which an openpore structure is required for suffienctly absorbing the solutioncomprising the colouring and the fluorescing agent and thus to achieve apenetration depth of 5 mm.

In contrast to the penetration depth aimed at in WO 2014/164199, a muchlower penetration depth of 500 μm at most is achieved according to theprocess of the present invention, due to the bismuth diffusing from thegas phase into the body, rather than by being contained in a solutionthat is absorbed by the body.

If step c) of the process of the present invention is carried out duringsintering, a penetration depth of 500 μm at most can be achieved whenapplying common sintering temperatures, and in particular a temperatureof about 1450° C., given that the densification of the material duringsintering takes place relatively rapidly. Thus, the skilled person, whohas become aware of the inventive process and its preferred embodiments,readily knows how to prepare the dental ceramic body.

As a result of the lower penetration depth, the dental ceramic body ofthe present invention allows to eliminate fluorescent properties inselected areas of the body in a very simple manner. Specifically, thiscan be achieved by removing material from the surface region or aportion thereof in the respective areas of the body.

Since by the process of the present invention bismuth diffuses into thematerial of the body, a concentration gradient within the surface regionis typically obtained. Specifically, the concentration of bismuthdecreases in direction from the surface of the body towards its coreregion in a gradual manner. Due to this concentration gradient, thepresent invention further allows attenuating the fluorescence intensityof the body by partially removing the material from the surface region.In other words, material can be abraded down to a depth, at which theamount of bismuth is low enough for providing the desired attenuatedfluorescence intensity.

In contrast to the body obtained according to WO 2014/164199, the dentalceramic body of the present invention allows for a post-processing inorder to further adjust the fluorescent properties of the body.

Preferably, the molar amount of bismuth contained in the surface regionis less than 0.5 mol-%, preferably less than 0.4 mol-%, more preferablyless than 0.3 mol-%, and most preferably less than 0.2 mol-%. Althoughsufficient for providing the desired fluorescent properties to be dentalceramic body, these amounts are still low enough to further decrease anypotential impact on the mechanical properties of the material.

It is further preferred that the amount of bismuth contained in thesurface region is higher than 0.06 mol-%, preferably higher than 0.08mol-%, more preferably higher than 0.1 mol-%, in order to providesufficient fluorescence to the body.

As mentioned, the dental ceramic body is particularly well suited forapplications for which no or only unsubstantial further machining isrequired in order obtain the final dental article. In particular, thedental ceramic body is a prosthetic element for use in a dentalrestoration, preferably a crown, a bridge, an implant, an abutment, anonlay and/or an inlay.

Alternatively to the embodiment, in which step c) is carried out duringsintering, the process of the present invention also encompasses theembodiment, in which the dental ceramic body or a precursor of thedental ceramic body is exposed to the bismuth containing atmosphere instep c), said dental ceramic body or precursor being non-densifiedand/or porous. In terms of a sintering process, a green body or a brownbody of the dental ceramic body can be subjected to the exposureaccording to step c). The term “brown body” thereby relates to the greenbody after burning off the binder.

In other words, step c) can be performed prior to the actual sinteringstep. Given the lower density of the material in comparison to thedensified material obtained during sintering, bismuth can diffuse deeperinto the porous ceramic body or precursor. When choosing a sufficientlylong time of exposure, this can lead to the point at which bismuth isdistributed throughout the whole porous ceramic body or precursor, whichcan then be subjected to the final sintering at a higher temperature toobtain the dense ceramic body.

For this alternative embodiment, the temperature of step c) ispreferably above the evaporating temperature of the bismuth compound,but below the final sintering temperature of the ceramic, andspecifically is in a range from 1100° C. to 1200° C.

The present invention, thus, also relates to a dental ceramic blockobtainable by the process specified above, the bismuth contained beingdistributed throughout the whole block. This dental ceramic block caneither be non-densified, i.e. in the pre-sintered state, or densified,i.e. in the sintered state.

Specifically, the present invention relates to a dental ceramic blockcontaining bismuth distributed throughout the whole block, the amount ofbismuth being higher than 0.06 mol-%, preferably higher than 0.08 mol-%,more preferably higher than 0.1 mol-%.

The features, which in the context of the process and the dental ceramicbody of the present invention have been presented as preferred, arelikewise preferred features of the dental ceramic block and of theprocess for preparing the dental ceramic block, respectively. Inparticular, the dental ceramic block is likewise based on zirconiaand/or alumina, as discussed in the context of the process.

Whereas for some applications the dental ceramic body is particularlywell suited for applications for which no or only unsubstantial furthermachining is required in order obtain the final dental article, thereare some applications, in which the final dental article is obtained bymilling a block of the dense ceramic material. This can e.g. be the casefor a dental implant. Apart final dental articles, such as prostheticelements for use in a dental restoration, dental implants,individualized abutments or complete dentures, the term “dental ceramicbody” also ecompasses dental ceramic blocks, in particular semi-finishedblocks or blanks, in particular blanks with pre-fabricated connectionsand block for further chair-side modifications.

For applications, in which the final dental article is obtained bymilling a block of the dense ceramic material, the methods according toWO 2013/022612 and WO 2014/164199 are unsuitable, since by the millingthe surface near region containing the fluorescent compound is lost.

In particular with regard to a dental ceramic body which after sinteringis to be milled into the final dental article, more particularly adental implant, it would thus be desirable to provide a process forproviding a fluorescent dental ceramic material which even after millingmaintains its fluorescent properties.

According to a second aspect, the problem to be solved by the presentinvention is to provide a process for providing a fluorescent dentalceramic body which after milling body into the final dental articlemaintains its fluorescent properties.

The problem of this second aspect is solved by the process for providinga fluorescent dental ceramic body disclosed herein.

The present invention thus also relates to a process for providing afluorescent, dense ceramic body based on zirconia and/or aluminacomprising the steps of

-   -   A) providing a ceramic precursor powder containing apart from        zirconia and/or alumina, respectively, bismuth oxide in an        amount of lower than 0.7 mol-%, and a binder.    -   B) pressing the ceramic precursor powder to form a green body,    -   C) debinding the green body obtained in B) to form a porous        brown body, and    -   D) sintering the porous brown body obtained in C) to obtain the        fluorescent, dense ceramic body.

As mentioned above, the ceramic is preferably zirconia, more preferablyyttria-stabilized zirconia.

In this regard, the ceramic precursor powder can specifically be azirconia powder to which bismuth-doped yttria powder is admixed. In thisspecific case, bismuth diffuses out of the bismuth-doped yttria duringsintering, which results in the doping of the yttria-stabilizedzirconia.

Alternatively, the ceramic precursor powder can be prepared by admixinga bismuth containing solution to the yttria-stabilized zirconia powder,which likewise results in the doping of the yttria-stabilized zirconia.

According to the invention, bismuth oxide is contained in the ceramicprecursor powder in an amount of lower than 0.7 mol-%. In this regard,it is particularly preferred that the amount of bismuth oxide is highenough to provide the desired fluorescent properties, but low enough notto interfere substantially with the colour of the ceramic body to beprovided.

In particular in view of providing sufficient fluorescence to be seen bythe human eye, the amount of bismuth oxide contained in the ceramicprecursor powder is preferably higher than 0.06 mol-%, more preferablyhigher than 0.08 mol-%, most preferably higher than 0.1 mol-%. Thus, theamount of bismuth or bismuth oxide being used as a fluorophor is higherthan if it was used for the sole purpose of providing a defined colourto the material, as it is taught in FR 2 781 366 A1, according to whichthe amount of bismuth oxide is in any case to be kept below 0.2 wt.-%,i.e. well below 0.06 mol-%, since this is an essential feature of itsteaching.

The ceramic precursor powder according to A) can, thus, in particular bereferred to as bismuth-doped zirconia, more particularly bismuth-dopedyttria-stabilized zirconia.

Bismuth-doped yttria-stabilized zirconia exhibits a particularly highemission intensity, which—without wanting to be bound by the theory—canbe explained by the fact that in the final dense ceramic body the maincrystalline phase is doped, i.e. the stabilized zirconia, rather thanthe yttria, which is contained in much lower concentration. Also withregard to the bismuth-doped yttria-stabilized zirconia obtainable by theprocess according to the second aspect, the tetragonal phase stabilityof zirconia is not influenced in a negative way by the doping withbismuth.

Specifically, bismuth oxide is not used in a colouring filling materialfor the purpose of providing a defined colour to the ceramic body.According to this specific embodiment, bismuth-doping serves the solepurpose for providing fluorescence to the ceramic body. In analogy tothe above and in further distinction to the teaching of FR 2 781 366 A1,the ceramic precursor powder is preferably devoid of iron (Fe), in orderto prevent quenching of the fluorescent properties provided by bismuth.

In the dental ceramic body obtained by this process, the fluorophorbismuth is homogeneously distributed throughout the volume of the body.After milling, i.e. after subtraction of the surface region in at leasta portion of the body, the fluorescent properties are fully maintained.

This is of particular relevance for preparing a dental implant or adental implant abutment made of a fluorescent ceramic material, as theimplant or abutment is typically obtained by milling it from a dentalceramic block.

Accordingly, it is preferred that the process further comprises step

E) milling the dental ceramic body to a dental article, in particular toa dental implant or a dental implant abutment.

As the case may be, step C) can further comprise the sub-step ofpre-sintering the green body after debinding. Thus, an intermediate bodywith good machinability is achieved, which can in particular bepreferred in view of the preparation of a dental implant or a dentalimplant abutment.

Preferably, the sintering of D) is carried out in the presence of abismuth containing atmosphere. Thus, the bismuth oxide vapour pressurecan be maintained suffienctly high in order to diminish or preventdiffusion of bismuth out of the ceramic material.

With regard to the composition and to the generation of the bismuthcontaining atmosphere, the features which have been described aspreferred for the process according to the first aspect likewise arepreferred for the process according to the second aspect.

Also with regard to the material of the dental ceramic body, thefeatures described as preferred for the process of the first aspect arelikewise preferred for the process of the second aspect.

As mentioned, the amount of bismuth contained in the dental ceramic bodyachieved by the process of the first aspect or by the process of thesecond aspect is in particular higher than 0.06 mol-%, preferably higherthan 0.08 mol-%, more preferably higher than 0.1 mol-%. Further, theamount of bismuth contained in the dental ceramic block is in particularlower than 0.7 mol-%, preferably lower than 0.5 mol-%, more preferablylower than 0.3 mol-%.

The present invention thus also relates to a dental ceramic body,specifically to a dental ceramic block as well as to a final dentalarticle, containing bismuth in an amount of higher than 0.06 mol-%,preferably higher than 0.08 mol-%, more preferably higher than 0.1mol-%, based on the total composition.

The present invention is exemplified and illustrated by way of thefollowing examples in combination with attached

FIG. 1 showing the emission spectra (for an excitation wavelength of 365nm) of various samples prepared according to the process of the presentinvention invention; and

FIG. 2 showing the excitation spectrum (for an emission wavelength of460 nm) of a sample prepared according to the process of the presentinvention invention.

EXAMPLES Example 1 Relating to the First Aspect of the Present Invention

1.1 g of partially stabilized zirconia powder containing 3.0 mol %ytrria (Tosoh TZ-3YSB-E) was pressed with 65 kN (resulting in a pressureof 171 MPa) to a disc-shaped green body having a diameter of 22 mm.

The resulting green body was then subjected to a heat treatment fordebinding (at about 300° to 350° C.) and burning the carbon residues (atabout 700° C.), followed by pre-sintering at 1050° C.

The pre-sintered body was then placed in a crucible together withpredefined amounts of a bismuth compound, namely of 1% bismuth nitratein nitric acid (obtained by adding 100 mg of bismuth nitratepentahydrate to 10 ml of 1% nitric acid) or of bismuth (III) oxide.

Specifically, an alumina vessel having the shape of a hollow cylinderwith an outer diameter of 20.5 mm and a height of 18 mm was put into acrucible with inner dimensions of 42×92×25.8 mm. The vessel was placedin a region of the crucible other than the region where the pre-sinteredbody was placed.

For each of the samples, different amounts of bismuth nitrate or bismuth(III) oxide were given into the alumina vessel and, in case of thebismuth nitrate being in solution, were dried in a drying chamber. Therespective amounts are given in Table 1:

TABLE 1 Mass of Volume of Atomic Sample Bismuth bismuth solution mass ofBi No. compound compound (μl) (μg) 1 Bismuth 0.1 10 43.08 nitrate 2Bismuth 0.5 50 215.41 nitrate 3 Bismuth 1.0 100 430.82 nitrate 4 Bismuth2 861.65 nitrate 5 Bismuth 5 2154.12 nitrate 6 Bismuth 7 3015.76 nitrate7 Bismuth 8 3446.59 nitrate 8 Bismuth 10 8969.90 oxide 9 Bismuth 10089699.3 oxide

Sintering of the pre-sintered body was then performed in the presence ofa bismuth containing atmosphere generated from evaporation of thebismuth compound. Specifically, dwelling was performed at a sintertemperature of 1450° C. for 2 hours.

As shown in FIG. 2, sample 3 prepared according to the process of thepresent invention produced an excitation maximum at 315 nm. As furthershown in FIG. 1, the emission maximum produced was at 455 or 460 nm,whereby the highest fluorescence intensity was achieved for the sampleusing 8.97 mg atomic mass of bismuth (sample 8).

Thus, both the use of bismuth nitrate as well as of bismuth oxide led tothe generation of a bismuth-containing atmosphere during the sinteringprocess and consequently to the incorporation of bismuth, specificallyin the form of bismuth oxide, in an amount sufficient to impartfluorescent properties closely resembling the one of a natural tooth.Specifically, a bismuth oxide containing atmosphere was generated due tothe evaporation of bismuth oxide in one case and to due to theevaporation and oxidation of bismuth nitrate in the other case.

Further experiments have shown that using a zirconia sample infiltratedwith a bismuth nitrate solution of higher concentration (100 mg/ml) asbismuth source likewise led to the generation of a bismuth containingatmosphere during sintering.

The visual inspection of the samples under UV-light showed that theupper side of the sample, i.e. the side that was directly exposed to thebismuth-containing atmosphere, was homogeneously doped with bismuth.Thus, a uniform incorporation of bismuth was achieved on this side.

The results shown in FIG. 1 further suggest that the fluorescenceintensity is tunable by the amount of bismuth compound put into thecrucible and, hence, the concentration of bismuth compound in thebismuth containing atmosphere.

A fluorescence intensity under 365 nm similar to the one of a naturaltooth was obtained for an atomic bismuth mass of 3.45 mg in thecrucible. Given the volume of about 100 ml of the crucible's innerspace, the optimum mass concentration of bismuth was therefore about0.035 g/l.

Example 2 Relating to the Second Aspect of the Present Invention

Preparation of Bismuth-Doped Yttria

A powder of bismuth doped yttria (Y₂O₃:Bi) was prepared by dissolving19.96 g of yttrium (III) nitrate hexahydrate (Y(NO₃)₃.6 H₂O) and urea(CH₄N₂O) in nitric acid (10%) and adding 2.15 ml of a solution ofbismuth (III) nitrate.pentahydrate (Bi(NO₃)₃.5 H₂O) in nitric acid (10mg/1 ml).

The mixture was then dried at 95° C. in a rotational evaporator at 200mbar vacuum.

The powder was then fired at 1000° C. for 1 hour in air in an aluminacrucible.

The cake received from firing were broken up and crushed to a coarsepowder. This powder was washed with deionized water to remove remainingflux and dried in a rotational evaporator. The powder was then sievedwith 250 μm mesh.

Preparation of Ceramic Precursor Powder

Zirconia powder TZ-3YSB-E was blended with Y₂O₃:Bi. Specifically, twomixtures of 10 g were prepared with either 1 wt.-% or 5 wt.-% of Y₂O₃:Bipowder according to Table 2.

TABLE 2 Percentage Mass of Mass of Y₂O₃:Bi Y₂O₃:Bi zirconia Samplepowder powder powder No. (wt-%) (g) (g) 10 1.0 0.1 9.9 11 5.0 0.5 9.5

The mixtures were given in mixer beakers and mixed in the speedmixer for1 minute at 800 rpm.

Samples were then pressed and sintered as described for Example 1 above.

Fluorescence measurments revealed for an excitation wavelength of 365 nman emission maximum at about 415 nm. The excitation maximum lies atabout 328 nm with another maximum at 304 nm.

The invention claimed is:
 1. A dental ceramic body based on zirconiaand/or alumina comprising: a core region being at least essentially freeof bismuth, and a surface region surrounding the core region andcontaining bismuth, wherein the surface region in which bismuth iscontained reaches down from the surface to a depth of 500 μm at most. 2.The dental ceramic body according to claim 1, wherein the molar amountof bismuth contained in the surface region is less than 0.5 mol-%. 3.The dental ceramic body according to claim 1, wherein the dental ceramicbody consists essentially of the core region and the surface region. 4.A process for providing a fluorescent dental ceramic body based onzirconia and/or alumina, the process comprising: A) providing a ceramicprecursor powder containing apart from zirconia and/or alumina,respectively, bismuth oxide in an amount that is lower than 0.7 mol-%and higher than 0.06 mol-%, and a binder, B) pressing the ceramicprecursor powder to form a green body, C) debinding the green bodyobtained in B) to form a porous brown body, and D) sintering the porousbrown body obtained in C) to obtain the fluorescent dental ceramic body.5. The process according to claim 4, wherein the sintering of D) iscarried out in the presence of a bismuth containing atmosphere.
 6. Theprocess according to claim 4, further comprising step E) milling thedental ceramic body to a dental article.